Galvanized upper coupler assembly

ABSTRACT

A trailer coupler assembly includes a grid assembly having a plate and a channel formed on the plate. A kingpin is received in the channel and is positioned to extend below a bottom surface of the plate. The channel is galvanized. A method of making a coupler assembly comprises the steps of providing a grid assembly having a channel, galvanizing the channel, and covering the channel.

This application claims priority to and the benefit of U.S. ProvisionalPatent Application No. 61/939,538 filed 13 Feb. 2014, the disclosure ofwhich is now expressly incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to a trailer coupler assemblyused to connect together trailers and vehicles, and more specifically toa partially galvanized upper coupler assembly.

BACKGROUND

Trailer coupler assemblies are used to connect trailers to vehicles,such as semi-tractors, trucks, automobiles, or railway cars, formovement of the trailer. Such cargo vehicles may include for examplesemi-trailers, van-type trailers, flatbed or platform type trailers,container chassis and cargo containers. One or more components oftrailer coupler assemblies may corrode and wear over time due in part tocorrosive forces, including sand, gravel, gas, oil, rain and otherliquid water, ice and snow, as well as the chemicals used to remove snowand ice. To protect from this corrosion, trailer upper couplerassemblies have been coated externally and internally with a variety ofmaterials and methods. Some existing systems have various shortcomingsrelative to certain applications. For example, a hot-dip process maylead to hydrogen embrittlement or other material changes of theunderlying steel. Accordingly, there remains a need for furthercontributions in this area of technology, including contributions thatreduce complexity, cost and weight of applications.

SUMMARY

The present disclosure may comprise one or more of the followingfeatures recited in the attached claims and combinations thereof, and/orone or more of the following features and combinations thereof.

In one aspect of the disclosure, an illustrative trailer couplerassembly is disclosed. Other embodiments include apparatuses, systems,devices, hardware, methods, and combinations for resisting corrosion.Further embodiments, forms, features, aspects, benefits, and advantagesof the present application shall become apparent from the descriptionand figures provided herewith.

In another illustrative aspect of the disclosure, a trailer couplerassembly comprises: a coupler grid plate, a kingpin channel formed onthe coupler grid plate, a kingpin coupled to the coupler grid plate, thekingpin being positioned within the kingpin channel to extend below abottom surface of the coupler grid plate, and a protective coatingapplied only to a selected area of the coupler assembly.

Various illustrative embodiments of a trailer coupler assembly areprovided. In one illustrative aspect, the trailer coupler assemblyillustratively comprises a coupler grid plate, a kingpin coupled to thecoupler grid plate, the kingpin being positioned to extend below abottom surface of the coupler grid plate, and a protective coatingapplied only to a selected area of the coupler assembly.

According to another illustrative aspect of the present disclosure, atrailer coupler assembly includes a coupler grid assembly. The couplergrid assembly may comprise a coupler grid plate, a support bracketcoupled to the grid plate, and a kingpin coupled to the coupler gridplate and the support bracket, the kingpin being positioned to extendbelow a bottom surface of the coupler grid plate, and a coating appliedto a selected portion of the trailer coupler. The trailer couplerassembly may further include an apron assembly.

Illustratively, the coupler assembly may further comprise structuredefining a kingpin channel, the defining structure including a pair ofspaced apart cross-members disposed generally perpendicular to spacedapart side members of a frame, and wherein the selected area that isselectively coated comprises a portion of the grid plate defining afloor of the kingpin channel, an upper portion of the kingpin, a portionof the cross-members defining the kingpin channel, and a plurality ofdividers disposed within the kingpin channel generally perpendicular tothe cross-members and parallel to the side members and to one another.The selected area or portion to be selectively coated or sprayedillustratively may extend laterally or transversely to each side of thekingpin about 12 inches to about 20 inches within the kingpin channel.The selected area to be coated may selectively include all structuredisposed within and defining this 24 to 40 inches of channel.

In one aspect, an illustrative trailer coupler assembly comprises: acoupler grid plate, a kingpin coupled to the coupler grid plate, thekingpin being positioned to extend below a bottom surface of the couplergrid plate, and a protective coating applied only to a selected area ofthe coupler assembly. The trailer coupler assembly may further comprisean apron assembly. Illustratively, the selected area comprises acritical area. For example the selected area may comprise the kingpinchannel. In another example the selected area is the kingpin channel,the portion of the kingpin residing within the kingpin channel, and thesupporting structure defining the kingpin channel and disposed therein.Such supporting structure may comprise the bracket. The selectivelycoated portion of the kingpin channel, including the sides and walls andfloor, may extend about 12 inches to about 20 inches on either side ofthe kingpin within the channel. In another example selected area is thekingpin channel, the kingpin and the supporting structure defining thekingpin channel and disposed therein. Illustratively, the selected areais the kingpin channel including a pair of spaced apart cross-membersdisposed generally perpendicular to spaced apart side members of aframe, a portion of the grid plate lying within the kingpin channel, anupper portion of the kingpin, and a plurality of dividers disposedwithin the channel generally perpendicular to the cross-members andparallel to the side members and to one another. In another example, theselected area is the kingpin channel including a pair of spaced apartcross-members disposed generally perpendicular to spaced apart sidemembers of a frame, a portion of the grid plate lying within the kingpinchannel, an upper portion of the kingpin, a support bracket disposedover the kingpin, an apron plate coupled with the kingpin, and aplurality of dividers disposed within the channel generallyperpendicular to the cross-members and parallel to the side members andto one another. In yet another example, the selected area comprises thekingpin, an area surrounding the kingpin within the kingpin channel, andan associated supporting structure of the kingpin. In one aspect, thecoating is applied in-line during a process of assembling the trailercoupler assembly. The coupler assembly may further comprise a coverplate disposed over the kingpin and coupled together with the frame. Thetrailer coupler assembly may further comprise drain holes formed in thegrid plate within the kingpin box. The drain holes may be formed in anarea outside the kingpin box. Illustratively, the coated couplerassembly weighs less than an alternative coupler assembly havingsubstantially identical structure to the illustrative coated couplerdisclosed herein, but wherein substantially all of that substantiallyidentical structure is coated. Illustratively, the selectively appliedcoating of the illustrative coupler assembly weighs between about 1.5pounds and 3.5 pounds. Further illustratively, the selective coatingweighs about 2.5 pounds. Illustratively, the selectively coated couplerassembly weighs about 35 pounds less than the alternate couplerassembly. Illustratively, the coated coupler assembly weighs about 70%to about 80% less than the alternate coupler assembly. Illustratively,the selective coating does not alter the material properties of thecoated material. In one aspect of the disclosure, the protective coatingis applied using a thermal spray system selected from the groupconsisting of an electric-arc spray system, a plasma-arc spray system,and a flame spray system. Illustratively, the protective coating isapplied using a thermal spray system selected from the group consistingof a conventional spray system, a high velocity spray system, ahigh-velocity oxy-fuel system, high-velocity air fuel, and a D-gun spraysystem. The protective coating may be applied using an automatedprocess, for example by a robot. Illustratively, the kingpin is made ofa first metal or metal alloy and the coating comprises a second metal ormetal alloy having a lower reduction potential than the first metal ormetal alloy. In one aspect of the disclosure, the coating includes ametal selected from the list of metals including zinc, magnesium, andaluminum. The coating may comprise zinc. In one aspect, the trailercoupler may further comprise a sacrificial anode coupled to the couplergrid plate. Illustratively, the kingpin is made of a first metal ormetal alloy and the sacrificial anode is made of a second metal or metalalloy having a lower reduction potential than the first metal or metalalloy. Further illustratively, the sacrificial anode may be made ofzinc, magnesium, or aluminum. In another aspect of the disclosure, thetrailer coupler assembly may further comprise a second coating.Illustratively, the second coating comprises a rust preventativecoating. The second coating may be an injection coating. The secondcoating illustratively may comprise a wax coating.

According to another aspect of the present disclosure, a couplerassembly line may include an initial manufacturing station and agalvanizing station. The initial manufacturing station may comprise astation for assembling the coupler assembly. The assembly lineillustratively may further include a coupler finishing station.Illustratively, the galvanizing station may include a coating boothconfigured to coat a selected portion of the coupler assembly.

In one aspect of the disclosure, the coating station may comprise acoating booth and a blasting booth. Illustratively, the coating stationcoats a selected portion or area of the coupler assembly. The selectedportion may comprise a critical portion of the coupler assembly. Forexample, the portion or area to be coated may comprise the kingpin. Inanother example, the selected area may comprise the kingpin, the kingpinsupporting structure, and the kingpin channel. In one aspect of thedisclosure, the coating station comprises a thermal coating station. Thecoupler assembly line may further comprise a robot. In another aspect,the coupler assembly line further comprises a finishing station.Illustratively, the finishing station comprises a top plate attachingstation. In another aspect, the finishing station comprises a secondcoating station. Illustratively, the second coating station isconfigured to coat the coupler assembly. Further illustratively, thesecond coating station may comprise an injection coating station.

The present disclosure includes an illustrative method of making apartially galvanized upper coupler assembly for use in a trailer. Themethod comprises the step of assembling together a coupler assembly or aportion thereof, for example a grid assembly. The grid assemblyillustratively is provided with an open kingpin channel. The methodfurther comprises galvanizing a selected portion of the kingpin channel.The selective galvanizing or coating step may include coating thekingpin. The method may further illustratively comprise closing thekingpin channel. The method may further comprise applying a secondcoating to the coupler assembly.

Another aspect of the disclosure is a method of making a vehicle couplerassembly comprising the steps of: assembling together a couplerassembly, the coupler assembly comprising a coupler grid plate, akingpin channel formed on the grid plate and generally comprising abottom portion comprising the grid plate, and a plurality of sideportions comprising a first pair of spaced apart cross-member sidewalls, and a pair of spaced apart side members generally perpendicularto the side walls and sandwiched therebetween, wherein the side wallsand the side members are attached together with the grid plate, a firstdivider disposed within the kingpin channel and generally perpendicularto the side walls and parallel to the side members, the dividers beingsandwiched between the walls, a second divider spaced apart from andparallel to the first divider, a kingpin box defined by the first andsecond dividers and portions of the cross-member walls therebetween, anda kingpin coupled together with the grid plate and extending below abottom surface of the coupler grid plate; applying a coating to aselected area of the coupler assembly, the selected area having asurface area less than a total surface area of the coupler assembly; andfinishing the coupler assembly.

In another aspect of the disclosure, a method of making a vehiclecoupler assembly comprises assembling together a coupler assembly. Thecoupler assembly illustratively comprises a coupler grid plate. Thecoupler assembly may further comprise a kingpin channel formed on thegrid plate and generally comprising a bottom portion comprising the gridplate and a plurality of side portions comprising a first pair of spacedapart cross-member walls and a pair of spaced apart side membersgenerally perpendicular to the walls and sandwiched therebetween,wherein the walls and the side members are attached together with thegrid plate. The illustrative coupler assembly may further comprise adivider disposed within the kingpin channel and generally perpendicularto the walls and parallel to the members, the dividers being sandwichedbetween the walls. The method may further comprise a second dividerspaced apart from and parallel to the first divider, and defining akingpin box therebetween, the kingpin box further bounded by portions ofthe respective walls. Illustratively, the coupler assembly furthercomprises a kingpin. The coupler assembly may further comprise a kingpinsupporting structure. The coupler assembly may further comprise a drainhole. The method illustratively may further comprise the step ofapplying a coating to a selected area of the coupler assembly.Illustratively, the selected area comprises the kingpin box.Illustratively, the selected area may comprise the kingpin channel. Inanother aspect, the selected area comprises the kingpin channel, thekingpin, the dividers, and the kingpin supporting structure.Illustratively, the method may further comprise the step of closing thekingpin channel. Further illustratively, the closing step may comprisedisposing a cover plate over the kingpin channel. A further illustrativeaspect may further comprise the step of attaching together the coverplate and the side members. Illustratively, the coating may comprise agalvanizing coating. The method illustratively may further comprise thestep of providing drain holes in the grid plate. The coating may beapplied at a station positioned in-line of a trailer couplermanufacturing line. Illustratively, the coating does not alter thematerial properties of the coated material. The coating may be appliedusing a thermal spray system. The selectively applied or selectiveprotective coating illustratively may be applied using a thermal spraysystem selected from the group consisting of an electric-arc spraysystem, a plasma-arc spray system, and a flame spray system. In anotheraspect, the selective protective coating may be applied using a thermalspray system selected from the group consisting of a conventional spraysystem, a high velocity spray system, a high-velocity oxy-fuel system,high-velocity air fuel, and a D-gun spray system. The protective coatingmay be applied using an automated process, may be applied manually, ormay be applied using a combination of automated and manual steps. Theautomated process may comprise a robot. Illustratively, the coating stepcomprises applying the coating to an approximate thickness of betweenabout 0.2 mils and about 20 mils. In another illustrative embodiment,the coating step comprises applying the coating to an approximatethickness of about 3.0 mils. In one aspect, the coating covers onlybetween about 1% and about 20% of the surface area of the coupler.Illustratively, the selectively applied coating weighs between about 1.5pounds and 3.5 pounds. Further illustratively, the selective coatingweighs about 2.5 pounds. In one aspect, the selective coating weighsabout 35 pounds less than an alternate coupler assembly havingsubstantially similar structure. Illustratively, the selectively coatedcoupler assembly weighs about 70% to about 80% less than the alternatecoupler assembly. Illustratively, the kingpin may be made of a firstmetal or metal alloy and the coating comprises a second metal or metalalloy having a lower reduction potential than the first metal or metalalloy. In one aspect, the selective coating includes a metal selectedfrom the list of metals including zinc, magnesium, and aluminum.Illustratively, the coating comprises zinc. Further illustratively, theselectively applied coating is zinc. In another illustrative aspect ofthe disclosure, the method may further comprise the step of providing asacrificial anode coupled to the coupler grid plate. Illustratively, thekingpin is made of a first metal or metal alloy and the sacrificialanode is made of a second metal or metal alloy having a lower reductionpotential than the first metal or metal alloy. Such a sacrificial anodemay be made from any one of zinc, magnesium, and aluminum.Illustratively, the sacrificial anode is a block of zinc. In anillustrative aspect, the method may further comprise the step ofapplying a second coating to the coupler assembly. Illustratively, thesecond coating may comprise a rust preventative coating. In one aspectof the disclosure, the second coating is an injection coating.Illustratively, the second coating is a wax coating. In one aspect, thecoating may be applied to an approximate thickness of between about 0.2mils and about 20 mils. Illustratively, the selectively applied coatinghas an approximate thickness of about 3.0 mils.

These and other features of the present disclosure will become moreapparent from the following description of the illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of a semi-trailer having an uppercoupler assembly employing features of the present disclosure;

FIG. 1A is a top cut-away view of a trailer coupler assembly of thepresent disclosure coupled to a portion of a trailer;

FIG. 1B is a cross-sectional view taken along line 1B-1B of FIG. 1A;

FIG. 2 is a top perspective view of the trailer coupler assembly showingtwo zinc block sacrificial anodes of the assembly;

FIG. 3 is an upper perspective view of an illustrative upper couplerassembly;

FIG. 4 is a cross-sectional view of another illustrative trailer couplerassembly taken along line 1B-1B of FIG. 1A;

FIG. 5 is an exploded perspective view of a portion of yet anothertrailer coupler assembly including zinc block sacrificial anodes coupledto a support bracket of the assembly;

FIG. 6 is a perspective view depicting an illustrative trailer coupler;

FIG. 7 is a flow chart depicting the steps of an illustrative method ofgalvanizing the kingpin channel; and

FIG. 8 is a diagrammatic view of an illustrative manufacturing line formaking an illustrative trailer coupler according to the illustrativemethod.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of the present invention, the drawings are not necessarilyto scale and certain features may be exaggerated in order to betterillustrate and explain the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to a number of illustrativeembodiments shown in the attached drawings and specific language will beused to describe the same. While the concepts of this disclosure aredescribed in relation to a trailer coupler assembly for use inconnecting a trailer to a semi-tractor or a railway car, it will beunderstood that they are equally applicable to other trailers andtrailer coupler assemblies generally, and more specifically to trailercoupler assemblies used with conventional box, van, or flatbed typetrailers, examples of which include, but should not be limited to,straight truck bodies, small personal and/or commercial trailers and thelike. Further, the concepts of this disclosure are similarly applicablefor use with any vehicle underbody or undercarriage, for any type ofvehicle, in applications where it is desirable to reduce corrosionand/or corrosion potential. Further, the concepts of this disclosure aresimilarly applicable for use with any vehicle underbody orundercarriage, for any type of vehicle, in applications where it isdesirable to reduce weight.

It should be understood that while the use of words such as preferablepreferably, preferred or more preferred utilized in the descriptionabove indicate that the feature so described may be more desirable, itnonetheless may not be necessary and embodiments lacking the same may becontemplated as within the scope of the invention, the scope beingdefined by the claims that follow. In reading the claims, it is intendedthat when words such as “a,” “an,” “at least one,” or “at least oneportion” are used there is no intention to limit the claim to only oneitem unless specifically stated to the contrary in the claim. When thelanguage “at least a portion” and/or “a portion” is used the item caninclude a portion and/or the entire item unless specifically stated tothe contrary.

Unless specified or limited otherwise, the terms “mounted,” “connected,”“supported,” and “coupled” and variations thereof are used broadly andencompass both direct and indirect mountings, connections, supports, andcouplings. Further, “connected” and “coupled” are not restricted tophysical or mechanical connections or couplings.

FIG. 1 depicts a cargo vehicle or trailer 11 having a floor assembly 20which includes an illustrative upper coupler assembly 10 in the forwardsection. The upper coupler assembly 10 illustratively comprises an apronassembly 110 and a grid assembly 115 coupled with a frame 34. Thekingpin or grid assembly 115 illustratively comprises a front mainchannel 25 and an aft channel 25, and a kingpin channel or box 50defined therebetween. A kingpin 16 may be disposed in the kingpin box50. A spool 16 a having lower portion 19 of kingpin 16 projects from theunderside of the floor assembly 20 and is positioned to engage atractor's fifth wheel or lower coupler (not shown). The kingpin channel50 may be covered or closed by a cover plate 15. Cover or top plate 15illustratively is shaped to fit and extend over channel 50. For example,in one illustrative embodiment, cover plate 15 is approximately 10inches wide and approximately 102 inches long, as are top flat faces orwalls 18C of each cross member 18. Cover 15 may be disposed or placed tocover the kingpin channel 50 and be coupled to the frame 34, as forexample by welding or other suitable means.

As shown in FIGS. 4-5, the frame 34 illustratively is formed of steeland includes a pair of side bars or side members 35 and a front plate ormember 36. The components of the frame 34 may be attached together bywelding. The front member 36 connects to an end of each side bar 35, andas such, the side members 35 are spaced apart from each other. Alternateframe 34 configurations may also be used.

The trailer coupler assembly 10 is coupled to the trailer 11 such thatthe trailer 11 may be connected to a semi-tractor (not shown) or othersuitable vehicle. Illustratively, the trailer coupler assembly 10 isprovided in and coupled to a floor region 21 (shown in FIG. 1B) of thetrailer 11 and is located near the front end of the trailer 11. Inparticular, the trailer 11 includes a floor having a sub-floor 20 and aflooring surface 22 to define the floor region 21 of the trailer 11therebetween, as shown in FIG. 1B. Illustratively, such flooring surface22 is removed from the trailer 11 shown in FIG. 1A in order to accessthe interior of the floor region 21. Further illustratively, the trailer11 is a box or van-type trailer including sidewalls 26, a roof 32(FIG. 1) coupled to the sidewalls, and doors (not shown) provided in oneor more of the sidewalls 26. In one illustrative embodiment, the trailercoupler assembly 10 illustratively may include a sacrificial element,for example first and second anodes 100, provided to retard thecorrosion of other surrounding components of the trailer couplerassembly 10.

Grid or kingpin assembly 115 generally comprises grid plate 12 orkingpin plate 12, two cross-members 18, bolsters 18 or box beams 18,cover plate 15, and a kingpin assembly comprising the kingpin 16, thelower portion 19 or spool 16 a. Welding together the cross members 18and the plate 12 defines the channel(s) or interior portion(s) 25. Thebolsters 18 may also be coupled together with the frame 34.Illustratively, the plate 12 may have a prepunched hole or aperture 17defined therethrough and configured to receive therethrough the kingpin16. In one illustrative embodiment, the kingpin may include a groovethat facilitates welding together the kingpin 16 and the plate 12.

Referring to FIGS. 1A-2 and FIG. 4, the illustrative grid assembly 115includes a support bracket 14 coupled to the plate 12, kingpin 16coupled to the support bracket 14 and positioned to extend downwardlyfrom the coupler grid plate 12 as shown in FIG. 1B, the plurality ofcross-members 18 coupled to the plate 12 and the bracket 14, and,optionally, a plurality of dividers or ribs 24 coupled to the plate 12and the cross-members 18. The coupler grid plate 12 forms the base ofthe trailer coupler assembly 10 and the bottom surface of the couplergrid plate 12 illustratively is generally flush with the bottom surfaceof the sub-floor 20. The coupler grid plate 12 typically occupiessubstantially the entire width of the trailer 11; however, it is withinthe scope of this disclosure to include a trailer coupler assemblyhaving a coupler plate of any suitable size. For example, anillustrative grid plate may measure about 34 inches wide and about 102inches or 8.5 feet long.

Referring to FIGS. 1A and 1B, the plurality of cross-members or bolsters18 may be mounted or coupled to the top surface of the coupler gridplate 12. Each cross-member 18 extends laterally across the width oftrailer 11 and may be connected to the frame 34. The cross-members 18are each formed in the shape of an upside-down “U” when viewed from theend (as shown in FIG. 1B) and each includes substantially flat or planartop and side walls and rounded corners. Illustratively, as shown inFIGS. 1A and 2, the two cross members 18 are parallel to andspaced-apart from each other such that a channel 50 is definedtherebetween. More specifically, as seen in FIG. 4, each cross-member orbolster 18 illustratively has first and second spaced apart vertical orside walls 18A, 18B and a third horizontal or top wall 18C. The firstand second walls 18A, 18B are attached to and extend upwardly from theplate 12, such that the first and second walls 18A, 18B are generallyperpendicular to the plate 12. The horizontal or top wall 18C connectsthe first and second walls 18A, 18B at the top ends thereof, whichillustratively are but need not be rounded. Bolsters or cross-members 18may comprise a unitary or monolithic structure, or they may compriseseparate components 18A, 18B, 18C that are connected or coupledtogether, for example by welding. Illustratively, respective sidewalls18B of each cross member 18 are spaced apart from each other in order todefine, along with grid plate 12, generally U-shaped channel 50therebetween. The aperture 17 (FIG. 3) in the wall or grid plate 12 ispositioned entirely between the walls 18B. Illustratively, the supportbracket 14 may be positioned between the respective cross-members 18 asbounded by a respective side wall 18B of each of the cross-members 18 asshown for example in FIG. 1B, FIG. 2 and FIG. 4. Additionalcross-members 18 may be provided if desired.

Looking now to FIG. 2, the illustrative support bracket 14, is generally“H-shaped” when viewed from above and is disposed in the space betweenthe cross members 18. Illustratively, the support bracket 14 includesspaced-apart side arm portions 28 (corresponding to the vertical sidesof the “H-shape”) and a bridge portion 30 (corresponding to thehorizontal middle of the “H-shape”) extending between and coupled to theside arm portions 28. In particular, the bridge portion 30 is coupled toan upper end of each side arm portion 28 while a lower end of each sidearm portion 28 is coupled to the grid plate 12. As such, the bridgeportion 30 of the bracket 14 is spaced-apart from the coupler grid plate12. Illustratively, the support bracket 14 is welded to the coupler gridplate 12; however, it is within the scope of this disclosure to couplethe bracket 14 to the plate 12 by any other coupling structure. As isdiscussed in greater detail below, the support bracket 14 is coupled tothe kingpin 16. While the particular support bracket 14 is shown anddescribed herein, it is within the scope of this disclosure to include atrailer coupler assembly having any suitable bracket for coupling thekingpin 16 to the coupler plate 12.

Dividers 24 of the trailer coupler assembly 10 illustratively arepositioned between the cross-members 18 on either side of the supportbracket 14, as shown in FIGS. 1A and 1B. Illustratively, the dividers 24are vertical plates secured to the coupler grid plate 12, the crossmembers 18 and the flooring surface 22. Dividers 24 illustrativelyconform to the shape of channel 50 and span the distance between walls18B. Illustratively, because dividers 24 span the height of flooringregion 21, the dividers 24 form substantially enclosed chambers betweena set of dividers 24 or between a divider 24 and the support bracket 14.Illustratively, the dividers 24 are each welded to the grid plate 12 andthe cross members 18; however, it is within the scope of this disclosureto couple the dividers 24 to the plate 12 and members 18 by any othersuitable coupling structure. Illustratively, the area bounded by thebolster walls 18B and the first pair of dividers 24 proximate to eitherside of the kingpin aperture 17, in other words adjacent to respectivearm portions 28, may be referred to as the kingpin box.

Lower portion 19 of the kingpin 16 is received through aperture 17 incoupler grid plate 12 and is illustratively located approximately 36inches rearward of a front end 27 of the trailer 11, as shown in FIGS.1B and 3. An upper portion 23 of kingpin 16 is secured to the bridgeportion 30 of the support bracket 14. Illustratively, an upper edge ofthe upper portion 21 of the kingpin 16 is received within an aperture 33of the bridge portion 30 and is welded thereto. An apron plate 29 of thetrailer coupler assembly 10 is coupled to the kingpin 16, as shown inFIG. 3, such that the upper portion 21 of the kingpin 16 is positionedabove the apron plate 29 and the lower portion 19 of the kingpin 16 ispositioned below the apron plate 29. When assembled, the bottom surfaceof the apron plate 29 is coupled to and adjacent the top surface of thecoupler plate 12. In accordance with conventional operation, the lowerportion 19 of kingpin 16 interfaces with a fifth wheel (not shown) of asemi-tractor or interfaces with a stanchion plate (not shown) of arailway car, for example. Illustratively, while various components ofthe trailer coupler assembly 10 are shown in FIGS. 1A-3, it is withinthe scope of this disclosure to include alternative trailer couplerassemblies having other suitable components coupled to a trailer topermit the trailer to be coupled to a semi-truck, for example. Forexample, the illustrative embodiment depicted in FIG. 4 includesstiffeners 124 spanning the forward or front main channel 25. Anotherillustrative embodiment (FIG. 6) depicts a flatbed trailer 211 having anillustrative coupler assembly 210 including illustrative grid assembly215. Illustratively, grid assembly 215 is substantially similar to gridassembly 115. For example, grid assembly 215, illustratively comprisesgrid plate 12, cross-members 18 coupled to grid plate 12 and definingtherebetween kingpin channel 50, and dividers 24 and kingpin 16 disposedwithin channel 50. Grid assembly 215 may but need not further includesupport bracket 14 and/or cover plate 15 (not shown in FIG. 6).Illustratively, coupler assembly 210 has a width of about 44 inches anda length of about five (5) feet. Illustratively, top flat faces or wallsof each cross-member 18 of coupler assembly 210 have a width of about 10inches and a length of about 44 inches. Cover plate 15 (if included) isapproximately 10 inches wide and approximately 44 inches long.

Illustratively, components of the trailer coupler assembly 10, 210including the kingpin 16, the coupler plate 12, the support bracket 14(if included), and the apron plate 29 (if included) are made of metaland/or metallic alloys, such as steel, which have high strength anddurability. As noted above, these components are welded to each other attheir connections, such as at the contact between the kingpin 16 and thesupport bracket 14 and the contacts between the support bracket 14 andthe cross members 18. However, it is within the scope of this disclosureto couple the components of the trailer coupler assembly 10 to eachother using other suitable fastening structures such as bolts, screws,rivets, epoxy, adhesives etc.

In an illustrative embodiment depicted in FIGS. 2 and 3, the anodes 100are depicted. It will be appreciated that anodes 100 are illustrativeonly and are not necessary. First and second zinc blocks 100 areattached to the coupler grid plate 12 adjacent the support bracket 14and the kingpin 16. Illustratively, the zinc blocks 100 operate assacrificial anodes to retard (e.g., delay) or even stop the corrosion ofthe surrounding steel components of the trailer coupler assembly 10,210. Illustratively, sacrificial anodes include a metal having a morenegative electrochemical reduction potential than any of the metal(s)used to form the surrounding components of the trailer coupler assembly10, 210 and the metal(s) used to weld the components of trailer couplerassembly 10 together. Stated differently, sacrificial anodes, such asthe illustrative zinc blocks 100, include a metal that will oxidize morereadily than any the metal(s) used in the components, fasteners, and/orwelding adjacent to and surrounding the sacrificial anodes. Furtherillustratively, while the blocks 100 of the trailer coupler assembly arezinc, it is within the scope of this disclosure to substitute or includeother suitable metals that oxidize more readily than the metal(s) usedto form the various components of the trailer coupler assembly 10.Examples include, but are not limited to, magnesium, aluminum, andalloys of zinc, magnesium, and aluminum. Furthermore, while the entiretyof the blocks 100 are generally formed of zinc, it is within the scopeof this disclosure to include sacrificial anodes which are onlypartially formed of one or more of the aforementioned or other suitablemetals.

As noted, in one illustrative embodiment zinc blocks 100 operate toretard or even prevent the corrosion of the components and welds oftrailer coupler assembly 10 which have a less negative electrochemicalreduction potential than the electrochemical reduction potential of thezinc blocks 100. Referring again to FIGS. 2 and 3, the trailer couplerassembly 10 includes the first and second zinc blocks 100 attached tothe coupler grid plate 12 adjacent to the support bracket 14 and thekingpin 16. As shown in FIG. 2, one of the zinc blocks 100 is coupled tothe plate 12 at a location adjacent to and aligned with one of the sidearm portions 28 of the support bracket 14. Illustratively, this zincblock 100 is spaced-apart from the left side arm portion 28, as shown inFIG. 2, outside the bracket 14. The other zinc block 100 isillustratively positioned between the side arm portions 28 at a locationabove the kingpin 16, as shown in FIG. 2. However, it is within thescope of this disclosure to couple the zinc blocks 100 to any suitablelocation on the coupler plate 12 in order to retard or prevent thecorrosion of adjacent metal components of the trailer coupler assembly10. For example, a zinc block may be coupled at any location inside oroutside the side arms 28 of the support block 14. The zinc blocks 100may also be attached to the coupler grid plate 12 at a location furtherfrom the bracket 14, such as within an interior portion or channel 25(shown in FIG. 1B) of one or more of the cross members 18. Further, thezinc blocks 100 may be positioned at a location between two adjacentdividers 24, for example.

Illustratively, each zinc block 100 is coupled to coupler plate 12 by abolt 102 received though through a hole 31 in the zinc block 100 and ahole 104 (shown in FIG. 3) in the coupler grid plate 12. A nut 108 isfastened to the bolt 102. Alternatively, hole 104 may contain threadingsuch that bolt 102 is fastened to coupler grid plate 12 withoutprotruding below the bottom surface of coupler grid plate 12. Further,aperture 31 in zinc block 100 may contain threading (not shown) suchthat zinc block 100 is threadably coupled to a screw (not shown) with orwithout the use of nut 108. Illustratively, bolt 102 and/or the screwmay be countersunk into the bottom surface of coupler plate 12 such thatthe head of bolt 102 or the screw does not substantially protrude belowthe bottom surface of coupler grid plate 12. As will be appreciated,numerous structures are available to attach the zinc block sacrificialanodes 100 to the coupler grid plate 12. While the zinc blocks 100 maybe attached in a permanent fashion by methods such as welding, the zincblocks 100 in the illustrated embodiment are removably attached tocoupler grid plate 12 so that the zinc blocks 100 may be replaced whenthey have wholly or partially lost the ability to retard corrosion ofthe surrounding trailer assembly components. As such, while each zincblock 100 is illustratively coupled to plate 12 through the use of bolt102 or a threaded screw, it is within the scope of this disclosure tocouple zinc blocks 100 to coupler plate 12 using other suitablefasteners such as nails, adhesives such as epoxy, welding, etc.

Illustratively, access ports, cutouts or holes 308, as well as drainholes 103, may be defined in the grid plate 12 as well as in the bottom20 (not shown). These access ports 308, 103, as well as other holes suchas for example holes 104 in the event blocks 100 and screws 102 areabsent, may be used to inspect the inner recesses of the channels, mayserve as drain holes, and/or may be used to allow spray access toaccomplish the spray galvanization and/or subsequent coating process.Holes 103, 104, 308 may be cut directly from the coupler grid plate 12and/or floor 20 during manufacturing of the trailer coupler assembly 10,210 or may be independently formed of the same or a different metal oralloy, as the coupler plate 12 itself. Illustratively, the access holes308 are generally oval in shape and may be equipped with similarlyshaped plugs the may be received in the holes 308. However, it is withinthe scope of this disclosure to include access holes and plugs of anysuitable shape or size. For example, the access holes and plugs may becircular 103, 104, rectangular, square-shaped, etc.

Illustratively, access plugs may be removably disposed in holes 308,such that servicing of the trailer coupler assembly 10, 210 includingapplying new spray or injection coatings, servicing support block 14,and replacing/servicing the zinc blocks 100, may be performed frombeneath the trailer 11.

Sacrificial anodes 100 illustratively are generally rectangular inshape, cylindrical in shape, or are T-shaped. However, anodes of anysuitable shape and size may be alternatively used with the couplerassembly 10. For example, anodes having rectangular, cubic, cylindrical,oval, and other configurations or combinations thereof may be used.

Further, while each sacrificial anode 100 is fastened to another one ofthe respective trailer coupler assembly components, such as couplerplate 12 and support bracket 14, using bolts or screws, it is within thescope of this disclosure to position sacrificial anodes within enclosedcompartments of a trailer coupler assembly as well. In particular, aplurality of sacrificial anodes may be disposed loosely within asubstantially enclosed chamber formed between a set of two adjacentdividers 24 or between a divider 24 and support bracket 14. Furtherillustratively, sacrificial anode 100 may be positioned loosely withinthe interior portion 25 of cross-members 18.

Illustratively, the structure for attaching sacrificial anodes 100 totrailer coupler assembly 10, 210 may be used in conjunction with oneanother and/or with other attachment structures. For example,sacrificial anode(s) 100 may be attached to coupler grid plate 12,sacrificial anode(s) 100 may be attached to support bracket 14, andsacrificial anode(s) 100 may be attached to access plugs (not shown).

Further, while sacrificial anodes 100 are illustratively coupled tocoupler grid plate 12, support bracket 14, and access plug(s), suchanodes 100 may be coupled to other components of coupler assembly 10,210 as well. For example, sacrificial anode(s) 100, may be coupled tokingpin 16, apron plate 29, cross-members 18, and/or dividers 24, forexample. Accordingly, the sacrificial anodes may be coupled directly orindirectly to any suitable component of coupler assembly 10, 210.

Illustratively, apron assembly 110 generally comprises a bottom plate,which may comprise the subfloor 20, and illustratively may include aplurality of vertical members or stiffeners or reinforcements ordividers 224. Illustratively, vertical members 224 and the bottom plate20 may be coupled together as for example by welding. The verticalmembers 224 and bottom plate 20 may also be coupled together with frame34. A front plate 36 may also be coupled together with the bottom plate20, as by for example and without limitation a seal weld, and with theframe 34. An apron channel cover or floor plate 37 may cover the apronchannel defined between opposing front plate 36 and main channel wall18A and opposing side members 35. Cover plate 37 may be attachedtogether with the frame 34, the main channel bolster 18 and/or thedividers 224. While not shown, an apron assembly may but need not beincluded in coupler assembly 210.

A method of manufacture or assembly 170 (FIG. 8) of upper couplerassembly 10, 210 including the galvanization of portions of the kingpinchannel 50 area will now be described. It should be understood thatwhile illustrative embodiments of upper coupler assembly 10, 210 aredescribed, multiple other possible embodiments exist, which could bemanufactured according to the method.

In an illustrative assembly line or manufacture or manufacturing line170 and process 170 (FIG. 8), each of the apron assembly 110 and thegrid assembly 115, 215 may be assembled as described herein as they movedown separate lines, for example on a roller conveyor, or down the sameline, or down a combination of separate and same lines. For example,apron assembly 110 may have bottom plate 20, vertical reinforcements224, frame 34 and front plate 36 coupled together on an apron assemblymanufacturing line 171 in one illustrative embodiment. An apron assemblycover or top plate 37 also may be positioned over the frame 34 andcoupled together therewith. Similarly, grid assembly 115, 215 may havegrid plate 12, cross members 18 and dividers 24 coupled together on aseparate or on the same assembly manufacturing line 171. The kingpin 16may be dropped in or inserted through aperture 17 and welded togetherwith plate 12. In one illustrative embodiment, stiffeners 124 may beincluded in forward or main channel 25. The apron assembly 110 and thegrid assembly 115 may be brought together in an abutting relationshipeither on the initial line 171 or on the finishing line 175.Illustratively, apron assembly 110 and grid assembly 115 may be weldedtogether, for example and without limitation by a seam weld. If gridassembly 215 is coupled together with an apron assembly, a seam weld maybe used.

Referring to FIG. 7 and FIG. 8, during assembly process 170, kingpinchannel or box section 50 of coupler 10, 210 may be galvanized or coated120, for example by thermal spraying 120. Illustratively, the entirelength and width of, including all upstanding bolster or cross-memberside walls 18B, frame side bars or side members 35 and dividers 24defining or disposed within the channel 50 may be sprayed, galvanized orcoated 140. This coating process 140 may be applied in-line 170 at agalvanizing, coating, or spraying station 173. If desired, galvanizingstation 173 could be located off the manufacturing line 170, however.Galvanizing station 173 illustratively may comprise a spraying, spray,coat or coating booth and, but not necessarily a blast or blastingbooth. For example, if a portion to be sprayed has an abrasive surface,then it may be desirable to grit blast or otherwise prepare or prep thatsurface to ensure good adhesion of the spray coat. For example, theillustrative apparatus 10, process 120 and assembly 170 may includeprepping or preparing, such as for example by abrading, the area orsurface to be coated, for example galvanized, prior to spray galvanizingthe desired surface or area. Illustrative examples of prepping thesurface may include for example and without limitation blasting,sanding, grinding, peening, and chemical etching. Blasting, for example,may be accomplished by sand blasting or grit blasting. Sanding andgrinding may illustratively be accomplished by using an abrasive pad orwheel. If, however, the portion to be sprayed or coated is not a surfacethat will be exposed to abrasion, then adhesion of the coating, which isprimarily a sacrificial layer, may not be necessary thereby obviatingthe need, but not necessarily the desire for a blast booth.

In an illustrative embodiment, galvanizing step 140, also referred to asapplying step 140 or spraying step 140 or coating step 140, may beincorporated into the manufacture line or process 170 at any desiredpoint prior to coupling cover plate 15 to grid assembly 115, or, ifincluded, to grid assembly 215. For example and without limitation,applying, galvanizing, coating or spraying step 120 could beaccomplished after grid assembly 115, 215 is assembled, after apronassembly 110 and grid assembly 115, 215 (if coupled to an apronassembly) are joined together, and/or after kingpin 16 is dropped intothe aperture in the grid plate spraying 120 could be accomplished beforeor after apron assembly 110 and grid assembly 115 are brought together,and before or after kingpin 16 is inserted into aperture 17 of gridplate 12. It will be appreciated that in the event grid assembly 215includes a cover plate 15, and/or is coupled to an apron assembly, thesame flexibility in incorporating the spraying step 140 would alsoobtain. In addition to spraying or coating inner surfaces of walls 18Band grid plate 12 that define channel 50, and coating the surfaces ofdividers 24, the applying or spraying step 140 may include coating orspraying kingpin 16 or a portion of kingpin 16, illustratively upperportion 23 and apron 29 (if included) which are disposed within thechannel, and supporting structure including for example bracket 14 (ifincluded). Similarly, if an anode 100 is included, it, along with bolt102, and nut 108, may be sprayed if desired. Illustratively, theselected area that is selectively sprayed or coated may be the structurewithin the channel 50 extending about 12 inches to about 20 inchestransversely from the kingpin within the channel. For example, theportion of the kingpin within the channel such as the upper portion 23and apron 29 (if included), the floor of the channel 12 within theselected area, the side walls 18B defining the channel within theselected area, the bracket or other support structure (if any), and thedividers if any within the selected area. One illustrative methodcontemplates galvanizing selected areas, for example channel 50including kingpin 16 and supporting structure 14 after initialmanufacturing or assembly 117, 130, and prior to closing the channelstep 150. During the closing step 150, cover plate 15 is disposed tocover channel 50. Cover plate 15 illustratively is attached or coupledtogether with the side members 35 of the frame 34. Cover plate 15 mayfurther be coupled or attached together with one or more of the dividers24 and the cross-members. In the event that the coupler assembly doesnot include a cover plate 15, then the closing step may be omitted.Illustratively, kingpin channel 50 and components disposed therein couldalso be sprayed by inserting a wand for example through any of holes103, 104, 308 even after the cover plate 15 has been attached. It willalso be appreciated, that other components, including other channels 25may be galvanized. For example, if main channel 25 includes stiffeners124 as in one illustrative embodiment, then channel 25 and/or thestiffeners 124 could also be galvanized as described. Illustratively,channel 25 and/or stiffeners 124 could be sprayed by inserting a wandthrough any of holes 308. So, too, the interior surfaces of bolster 18and/or stiffeners 124 could be sprayed prior to being attached to gridplate 12. Further illustratively, top face 18C of main channel bolster18 may be attached to side walls 18A, 18B after the main channel area 25and/or stiffeners 124 are sprayed. It will also be appreciated that anyother area of coupler assembly 10, 210 including for example frontdividers 224 and/or bottom plate 20, and/or front plate 36, and/or frame34 may be sprayed.

The spraying or galvanizing step 140 may be accomplished by any suitablemethod. For example, it could be applied manually by a person forexample, or through an automated machine as for example by a robot.Illustratively, the coating material and method of deposit may be chosenas well. Examples of suitable coatings include, but are not limited to,zinc, magnesium, aluminum, and alloys of zinc, magnesium, and aluminum.Examples of suitable methods of deposit include thermal spray systemssuch as for example and without limitation an electric-arc spray system,a plasma-arc spray system, detonation gun system, and a flame spraysystem. Illustrative flame spray systems may include powder or wiresystems, including conventional, high velocity, high-velocity oxy-fuel(HVOF), high-velocity air fuel (HVAF), and D-gun spray systems. Thegalvanizing or coating step may also be customized to define the area ofcoverage and the thickness of the spray deposited over that area. Thethickness may be defined or built, for example by the amount of timethat the spray coating is applied and/or by the number of coats that areapplied. Illustratively, the coating thickness could be between about0.2 and about 20 mils. In one embodiment the coating thickness is about3.0 mils.

By galvanizing selected areas, for example critical areas, theillustrative method saves weight and expense. For example, anillustrative embodiment that galvanizes channel 50, kingpin 16 andsupporting structure may add a protective zinc coating weighing about2.5 pounds as compared to a zinc coating weighing about 35-40 pounds ormore using a conventional method such as for example hot-dipgalvanizing. Illustratively, a coating weight reduction of 70% to 90%for a coupler assembly 10, 210 may be realized by using the illustrativemethod. Indeed, the illustrative method can be used to target onlycritical areas, for example structural areas that are prone tocorrosion. The illustrative spray methods allow for the use of lowersubstrate peak temperatures relative to for example hot-dip galvanizing.The relatively lower temperatures of the illustrative process protectthe zinc coating from heat generation and do not therefore alter theunderlying material properties, for example the molecular or physicalstructure or properties of the coated metal or material.

Coupler finishing stations 175 may include a top plate attaching orattachment station and a second coating station. In the couplerfinishing stations 175, among other things, closing the kingpin channelstep 150 may be completed and coupler assembly 10, 210 illustrativelymay be coated with another rust inhibiting or rust preventative coat.Even areas that have been galvanized during the spraying step 140 may befurther coated. Illustratively, this further coating may be an injectioncoating of for example and without limitation a wax coating, an epoxypaint, or a water emulsified asphaltic coating. For example, thewax-based coating may be applied to the underbody, including for examplethe outer facing surfaces of grid plate 12 and subfloor 20. In addition,the wax-based coating may be injected into the various channels 25, 50of the coupler assembly 10 for example through a high-pressure wandinserted into holes 308 and/or holes on the weld reinforcements. Whilethis injection coating will protect the portions that have not beengalvanized, it may also mix with the particles of the spray coating fromspraying step 140 that did not get fully fused to the assembly metal,for example zinc particles, which particles will be retained and willserve as further sacrificial material to further protect the galvanizedareas.

While the disclosure has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asexemplary and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of thedisclosure are desired to be protected.

What is claimed is:
 1. A method of making a vehicle coupler assemblycomprising the steps of: assembling together a coupler assembly, thecoupler assembly comprising a coupler grid plate, and a kingpin coupledtogether with the coupler grid plate and extending below a surf ace ofthe coupler grid plate; thereafter applying a coating to a selected areaof the coupler assembly, the selected area having a surface area lessthan a total surface area of the coupler assembly; and finishing thecoupler assembly.
 2. The method of claim 1 wherein the applying stepcomprises applying the coating to an approximate thickness of betweenabout 0.2 mils and about 20 mils.
 3. The method of claim 1 wherein theselected area is defined by a pair of spaced apart and generallyparallel cross-members and a pair of spaced apart and generally parallelfirst and second dividers, the pair of dividers being disposed generallybetween and parallel to the pair of spaced apart cross-members; andwherein the coating galvanizes the selected area of the couplerassembly.